Sheet Metal Composite Flanging Welding Joint
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Solution Overview
Problem
Existing methods for joining sheet metal components, such as welding and soldering, face limitations in flexibility and quality of the bond, particularly in forming complex edge profiles and achieving a rigid, noise-free, and sealed joint.
Innovation Solution
A method combining flanging with welding or soldering, where the outer sheet is flanged to form a beaded edge that creates a lap joint with the inner sheet, using a tool that integrates flanging and welding/soldering processes, allowing for a continuous seam that enhances rigidity, noise reduction, and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flanges are formed in a press during plastic forming, then joining is achieved, but the achievable flange geometries are limited due to demolding requirements
Solution Approach 1:
The forming process is segmented into two distinct stages: first forming the basic flange geometry in the press, then performing secondary forming of the free edge in a subsequent operation. This allows the flange to achieve complex geometries that would be impossible in a single pressing operation, while maintaining manufacturing efficiency by dividing the process into manageable steps.
Solution Approach 2:
The basic flange structure is formed in advance during the main pressing operation, preparing the workpiece for the subsequent free edge forming. This preliminary action creates a foundation that enables the second forming step to achieve complex edge profiles without requiring complete re-forming of the entire flange structure.
2Shape
If conventional bending fixtures are used for subsequent forming of flanges, then complex edge profiles can be achieved, but the fixtures are bulky and inflexible
Solution Approach 1:
The forming system transitions from static, bulky fixtures to a dynamic roller-based system. The rollers can be positioned and adjusted along the flange length, enabling flexible formation of various edge profiles. The system adapts to different geometries by changing roller positions and configurations rather than requiring different bulky fixtures for each profile type.
Solution Approach 2:
Complex mechanical fixtures are replaced with a more versatile roller-based forming system. The rollers provide the necessary forming action through controlled rolling motion, eliminating the need for large, inflexible fixtures while achieving the same or better edge profile complexity through a more adaptable mechanism.
3Strength
If sheets are joined by conventional folding methods, then joining is achieved, but the joint lacks rigidity and allows noise from relative movement
Solution Approach 1:
The folding and welding processes are merged into a single integrated operation. The flange is folded and simultaneously welded to the adjacent sheet, creating a joint that combines the form-fit connection of folding with the rigid, noise-free connection of welding. This eliminates relative movement between sheets while maintaining the benefits of the folded configuration.
Solution Approach 2:
The joint creates a composite structure combining folded metal layers with weld material. This composite construction provides both the geometric interlocking of the folded flange and the strong, rigid bonding of the weld, resulting in a joint that is both stiff and noise-free while maintaining structural integrity.
4Reliability
If a continuous weld seam is produced along the flanged edge, then joint quality and sealing are improved, but the process requires integration of flanging and welding operations
Solution Approach 1:
The flanging and welding operations are merged into a single integrated process step. The equipment combines the rolling mechanism for flange formation with the welding system, allowing the flange to be formed and welded continuously in one pass. This integration ensures consistent joint quality and sealing while managing the complexity through unified process control.
Solution Approach 2:
The process maintains continuous action by performing flanging and welding simultaneously in a continuous operation rather than as separate discrete steps. The roller forms the flange edge while the welding system concurrently applies the weld seam, ensuring uninterrupted production flow and consistent joint quality throughout the entire flange length.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a stiffer, noise-free, and sealed sheet metal composite with a complex edge profile, suitable for vehicle manufacturing, offering improved flexibility and quality over conventional methods by ensuring a continuous, rigid weld or soldered seam along the entire length of the joint.
Implementation Method 1
a welding or brazing process
Implementation Method 2
a welding or brazing process
Implementation Method 3
The flange is folded around the flanged edge of the outer sheet by means of a flanging element moved longitudinally along the flanged edge
Data Source
Figure 1~6
Figure 7~8
Figure 9~10
AI summary
The invention concerns a sheet-metal composite, comprising: a) an outer sheet (1) with a flange (1c; 1d; 1e) turned over by rolling or sliding flanging about a flanging edge (1b), b) an inner sheet (2), which with the flange (1c; 1d; 1e) forms a joint (3; 6; 8), c) and a welded or soldered seam (4; 5; 7) and created on or in the joint (3; 6; 8), firmly connecting the sheets (1; 2) to each other. Furthermore, the invention relates to a method for joining sheets and to a device for flanging and welding or soldering. The device comprises: e) a tool head (10), f) a flanging element (13; 13') for rolling or sliding flanging, arranged on the tool head (10) and g) a welding or soldering tool (15) arranged on the tool head (10), h) wherein the flanging element (13; 13') and the welding or soldering tool (15) are arranged in such a way that the flanging element (13; 13') forms a pressing device for a welding or soldering process that can be carried out with the welding or soldering tool (15).